Composite products and manufacturing method

ABSTRACT

A composite product and a method of manufacturing the composite product are disclosed. The composite product includes (a) a polymeric material binder and a metal-bearing material or (b) the polymeric material binder and a carbon-bearing material. The 5 method includes heating and mixing the components of the composite product and thereafter forming the heated mixture into a final product shape, with the heating step being sufficient to melt at least a part of the polymeric material binder to facilitate forming the product.

The present invention relates to composite products and to a method ofmanufacturing the products.

The present invention relates particularly, although by no meansexclusively, to composite products that are made from recycled products.

The present invention relates particularly, although by no meansexclusively, to composite products that are suitable for use in hightemperature methods.

The term “high temperature methods” is understood herein to mean methodsthat operate at temperatures greater than 400° C., typically at least600° C.

Examples of high temperature methods are methods that are carried out inmetallurgical furnaces such as steelmaking furnaces. In these methodsthe composite products of the present invention are intended to provideany one or more of metal bearing units and a source of energy.

Other examples of high temperature methods are methods that are carriedout in power stations and kilns, such as cement making kilns, thatrequire heat to be generated by fossil or engineered fuels. In thesemethods the composite products of the present invention are intended toprovide a source of energy as a replacement of fossil fuels.

The present invention is not confined to composite products that aresuitable for use in high temperature methods. By way of example, thecomposite products of the present invention are suitable for use asbuilding materials or as protective materials for building and wearresistant materials (e.g. for wear resistance or corrosion resistance),such as alternatives to timber products and steel products.

The present invention is based on the use of a polymeric material as abinder to hold together particles of a metal-bearing material and/or acarbon-bearing material in a composite product that comprises (a) thepolymeric material and the metal-bearing material or (b) the polymericmaterial and the carbon-bearing material or (c) the polymeric materialand the metal-bearing material and the carbon-bearing material.

The present invention is also based on manufacturing these compositeproducts by a combination of heating and mixing the components of thecomposite product, with the heating step being sufficient to melt atleast a part of the polymeric material binder to facilitate forming theproducts.

The present invention provides a method of manufacturing a compositeproduct in the form of (a) a polymeric material binder and ametal-bearing material or (b) the polymeric material binder and acarbon-bearing material that comprises heating and mixing the componentsof the composite product and thereafter forming the heated mixture intoa final product shape, with the heating step being sufficient to melt atleast a part of the polymeric material binder to facilitate forming theproduct.

The heating and mixing steps may be carried out in the order describedin the preceding paragraph or in the reverse order or simultaneously.

The term “metal-bearing material” is understood herein to mean anymaterial that can be processed in a high temperature method such as ahigh temperature metallurgical method carried out in a metallurgicalfurnace to produce a metal product. The term “metal” is understoodherein to include metal alloys. Steelmaking, particularly electric arcsteelmaking, is one metallurgical method of particular interest to theapplicant. Other metallurgical methods include, by way of example, basicoxygen steelmaking and ironmaking methods. The present invention is notconfined to high temperature metallurgical methods. The metal-bearingmaterial may be a recycled material.

The method of manufacturing the composite product that comprises thepolymeric material binder and the metal-containing material may includemixing other materials, such as materials that are sources of carbonother than the polymeric material binder, with the metal-bearingmaterial and the polymeric material.

The other sources of carbon may comprise any one or more of biomass,flyash, rubber, paper, coke fines, char fines, coal fines, toner fromprinters and photocopying machines, and any other suitable organicmaterial. It is noted that, typically, in addition to containing carbonin the form of carbon black, toner contains metal-containing particles(iron oxides) and polymeric material. The other sources of carbon may berecycled materials. The other sources of carbon may be virgin materials.

The other materials may include burnt lime, dolomite, and magnesite.

The method may comprise controlling the method and the selection of themetal-bearing material when present), the carbon-bearing material whenpresent), and the polymeric material binder to produce a product havinga required porosity. There may be situations in which it is desirablethat the product be non-porous. There may be other situations where thepreferred chemical reactions in the high temperature method, such as ahigh temperature metallurgical method, may make it desirable for theproduct to have a level of porosity. For example, it may be desirablefor chemical reactions to take place within the product within thefurnace, in which case a level of porosity to facilitate escape ofvolatilised reaction products may be desirable.

The method may comprise mixing the metal-bearing material and thepolymeric material binder so that there is a uniform dispersion of themetal-bearing material through the product.

The method may comprise mixing the carbon-bearing material and thepolymeric material binder so that there is a uniform dispersion of thecarbon-bearing material through the product.

The method may comprise heating the mixture of the components of theproduct at a temperature that is sufficiently high to completely meltthe polymeric material binder. The temperature may be any suitabletemperature having regard to the particular selection of the polymericmaterial binder, the other components of the mixture, and therequirements of the particular method of forming the composite product.By way of example, in the case of a polymeric material binder in theform of low density polyethylene, typically the temperature is of theorder of 150-175° C.

The method may comprise selecting the metal-bearing material and thecarbon-bearing material so that these materials remain as solids duringthe heating step.

The method may comprise controlling the method and the selection of themetal-bearing material when present), the carbon-bearing material whenpresent), and the polymeric material binder to produce a product havinga required density. For example, when the product is a feed material fora steelmaking process it may be preferred that the product have adensity that allows the product to float on a molten metal pool thatforms in the process.

The metal-bearing material and the carbon-bearing material may be in aparticulate form.

By way of particular example that is relevant to steelmaking methods,the metal-bearing material may be in the form of iron-bearing particles.

The iron-bearing particles may be in the form of fines.

By way of particular example, the iron-bearing particles may be in theform of mill scale fines or baghouse dust or other by-products from asteelmaking plant or an ironmaking plant.

In the context of iron-bearing particles for use in making steel in anelectric arc steelmaking furnace, the term “fines” is understood hereinto mean particles that have a major dimension of less than 6 mm.

In a wider context of metal-bearing particles for use in hightemperature methods in metallurgical furnaces, the term “fines” isunderstood herein to mean particles that have a major dimension of lessthan 6 mm.

The use of the polymeric material as a binder for metal-containing orcarbon-containing materials in the composite product of the presentinvention is not confined to composite products for high temperaturemethods carried out in metallurgical furnaces and extends to hightemperature methods generally that require the composite product of theinvention. In this context, the present invention is not confined tofines and extends to metal-bearing and to carbon-bearing materials thathave a major dimension of greater than 6 mm.

The polymeric material binder may be any suitable material. An importantrequirement of the polymeric material binder is that it be capable ofacting as a binder of the other components of the composite productunder the specified materials handling and operational conditions forthe product. By way of example, the specified conditions may includestorage for prolonged periods in the outside atmosphere. By way offurther example, the specified conditions may include particularmaterials handling requirements for the product.

The polymeric material binder may be a recycled polymeric material.

The polymeric material binder may be a recycled polyethylene such as alow density polyethylene or a high density polypropylene or a recycledpolypropylene.

The carbon-bearing material may be in the form of biomass, flyash,rubber, paper, coke fines, char fines, coal fines, used toner fromprinters and photocopying machines, and any other suitable organicmaterial. The carbon-bearing material may recycled materials. Thecarbon-bearing material may be virgin materials.

The method may include any suitable forming step for forming a finalproduct shape.

The forming step may be any one of an extrusion step, a moulding step(including injection moulding), and a briquetting or other type ofpressing step.

By way of example, step (c) may include forming the heated mixture intothe composite product by extruding the heated mixture.

The extrudate may be in the final product shape.

Alternatively, it may be necessary to cut the extrudate to form thefinal product shape. For example, step (c) may include forming acontinuous extrudate and thereafter cutting the extrudate as it emergesfrom the extruder into the final product shape.

In a situation in which the extrudate emerges from the extruder as acontinuous “rope” (of small or large cross-section), the method mayinclude cutting the rope into smaller lengths, whereby the smallerlengths of the extrudate form the product.

The final product shape may be any suitable shape and any suitable size.

The shape and size of the final product shape may be determined havingregard to the materials handling and process requirements for themetallurgical method and metallurgical furnace in which the product isto be used.

The product may be in the form of pellets.

The product may be in the form of granules.

The product may be in the form of larger products that can be describedas blocks, pigs, patties, plugs and pucks.

The larger product may have a major dimension of at least 10 cm.

The larger product may have a major dimension of at least 15 cm.

The larger product may be at least 1 kg.

The larger product may be at least 2 kg.

The larger product may be at least 3 kg.

The larger product may be less than 10 kg.

In any given situation, the factors affecting the shape and the size ofthe product may include the following factors.

-   -   The product should have sufficient strength and toughness to be        able to be handled within a high temperature processing plant        such as a metallurgical plant and to be charged into a high        temperature furnace such as a metallurgical furnace in the plant        without significant breakdown of the product into smaller sized        products, with generation of fines outside and/or inside the        furnace.    -   The product should be sufficiently large and have required        mechanical properties such as strength to withstand the high        temperature and reactive conditions in the high temperature        furnace such as the metallurgical furnace to facilitate        controlled dissolution of the product in the furnace over a        required time period. Depending on the high temperature method,        this time period may be a relatively short time period or a        longer time period. The required dissolution rate may vary        depending on the chemical reaction requirements of the high        temperature method and the overall time period of the method.        For example, in some methods it may be important to have        combustion of combustible components in the product as soon as        possible. In other situations, it may be important to have        relatively slow dissolution of the product so that there is        consumption of the product during the whole operating period of        the method.

The present invention also provides a composite product that comprises ametal-bearing material and a polymeric material that acts as a binderfor the metal-bearing material.

The product described in the preceding paragraph may include othermaterials, such as materials that are sources of carbon other than thepolymeric material binder.

The present invention also provides a composite product that comprises acarbon-bearing material and a polymeric material that acts as a binderfor the carbon-bearing material.

The product described in the preceding paragraph may include othermaterials, such as a metal-bearing material.

The product may comprise a continuous network of the polymeric materialand a uniform dispersion of the metal-bearing material or thecarbon-bearing material.

The product may be a porous product.

The product may be a non-porous product and hence be at leastsubstantially waterproof. This is an advantageous feature in situationswhere any one or more of the components of the product is susceptible totaking up moisture while being stockpiled or transported. For example,this is particularly the case with products that include biomass as thecarbon-bearing material of the product.

The product may comprise an outer covering of the polymeric material.

The covering may make the product non-porous.

In addition or alternatively, the covering may thereby encapsulate finesin the product and minimise the release of the fines during materialshandling and transportation.

In any given situation, the relative amounts of the polymeric bindermaterial, the metal-bearing material (when present), the carbon-bearingmaterial (when present) and other materials will be a function offactors such as the binder requirements for the composite products, therequirement for metal-bearing materials in an end-use application forthe products, and the energy requirements for the products in theend-use application.

The polymeric material binder may comprise greater than 10 wt. % of theproduct.

The polymeric material binder may comprise greater than 15 wt. % of theproduct.

The polymeric material binder may comprise less than 50 wt. % of theproduct.

The polymeric material binder may comprise less than 45 wt. % of theproduct.

The polymeric material binder may have a vaporisation temperature lowerthan the temperature of a molten bath in the metallurgical furnace.

The polymeric material binder may be a recycled polymeric material.

The polymeric material binder may be a recycled polyethylene such as alow density polyethylene or a high density polyethylene or a recycledpolypropylene.

The metal-bearing material may be in the form of iron-bearing particles.

The iron-bearing particles may be in the form of fines.

The iron-bearing particles may be in the form of iron oxide particles.

The iron-bearing particles may be in the form of mill scale fines and/orbaghouse dust or other by-products from a steelmaking plant.

The carbon-bearing material may be in the form of particles of biomass,flyash, rubber, paper, coke fines, char fines, used toner from printersand photocopying machines, and any other suitable organic materials. Thecarbon-bearing material may recycled materials. The carbon-bearingmaterial may be virgin materials.

The product may be made completely from recycled materials, with each ofthe polymeric binder material and the metal-bearing material (whenpresent) and the carbon-bearing material (when present) being recycledmaterials.

The recycled materials may be obtained from any suitable source.

By way of example, the metal-bearing units may be in the form of millscale fines, the polymeric binder material binder in the form ofrecycled polyethylene, and the carbon-bearing units may be in the formof coke fines or recycled rubber.

The product may be any suitable size and shape. The product shape andsize may be as described above.

The product may be suitable for use in a high temperature method.

The product may be suitable for use as a source of energy as areplacement for fossil fuels in power stations and kilns, such as cementmaking kilns, and other applications that require heat to be generatedby fossil fuels. When used as a source of energy, the product may bedescribed as an “engineered fuel”.

The product may be suitable for use as building materials or asprotective materials for building materials (e.g. for wear resistance orcorrosion resistance) or as protective materials for mining consumables(e.g. for wear resistance on mining consumable parts for mineralprocessing or mining extraction equipment), such as alternatives totimber products and steel products.

The present invention also provides a high temperature method thatcomprises supplying the above-described composite product that containsmetal-bearing units and carbon-bearing units (a polymeric materialbinder) as a feed material for the method.

The high temperature method may be a method for producing a molten metal(which term includes a metal alloy, including a ferroalloy) in ametallurgical furnace.

The method may be a method of producing steel.

The steelmaking method may be an electric arc steelmaking method.

The steelmaking method may be a basic oxygen steelmaking method.

The method may be a method of producing iron.

The present invention is based on a realisation of the applicant duringthe course of a research and development project that it is possible toproduce a composite product that comprises metal bearing units, moreparticularly, iron-bearing units in the form of mill scale fines and apolymeric material binder in the form of recycled low densitypolyethylene that is well-suited in terms of materials handling,chemistry, and processing properties for use in an electric arc furnacesteelmaking method. In particular, the applicant found in the course ofthe project that the polymeric material acted as an effective binder forthe iron-bearing fines in the composite product and provided a source ofenergy.

The present invention is also based on a realisation of the applicantduring the course of the project that it is possible to produce acomposite product that comprises carbon-bearing units in the form ofcoke fines and a polymeric material binder in the form of recycled lowdensity polyethylene that is well-suited in terms of materials handling,chemistry, and processing properties for use in an electric arc furnacesteelmaking method.

The present invention is also based on a realisation of the applicantduring the course of the project that hot forming, for example by hotextrusion, of mixtures of the above-described metal-bearing units and/orcarbon-bearing units and polymeric material binder at temperatures atwhich at least part of the polymeric material binder had melted and theother components of the mixture remained as solids is an effectivemethod of producing composite products with the required materialshandling, chemistry, and processing properties for use in an electricarc furnace steelmaking method.

The present invention is also based on a realisation of the applicantduring the course of the project that the metal-bearing based compositeproduct and the carbon unit based composite product of the invention haswider end-uses than steelmaking. In particular, the applicant hasrealised that the carbon unit-based composite product of the inventionhas applications as a replacement for fossil fuels in power stations andkilns, such as cement making kilns, and other applications that requireheat to be generated by fossil or engineered fuels.

The research and development project included laboratory work on a widerange of products having 10-45 wt. % of a polymeric material in the formof low density polyethylene in accordance with the present invention.

The laboratory work included work on composite products comprisingmetal-bearing, specifically iron-bearing, material in the form of millscale and the polymeric material in the above ranges. The laboratorywork found almost 100% reduction of the iron oxide in these products tomolten iron.

The laboratory work also included work on composite products comprisingcarbon-bearing material in the form of coke fines and the polymericmaterial in the above ranges.

One example of the product had a composition of 24 wt. % low densitypolyethylene binder, 1 wt. % processing aid, 75 wt. % coke fines andother carbon-containing material.

The research and development project also included a 1 tonne trial of asample composition of the product of the present invention in anelectric arc steelmaking furnace of the applicant.

The sample product for the trial was extruded successfully on a standardcommercial hot extruder.

The continuous “rope” that was produced by the extruder was formed intolarge “pattie” shapes, of the order of 3 kg.

The sample product had a composition of 24 wt. % low densitypolyethylene, 1 wt. % processing aid, 7 wt. % coke, and 68 wt. % millscale.

Composition by Material Mill scale 68 Coke fines 7 Recycled LDPE 24Processing Aid 1

Composition by Element Iron (~75 wt. % Fe in mill scale) 51 Carbon (~85wt. % C in LDPE/~85 wt. % C in coke) 26 Oxygen (~25 wt. % O in millscale) 17 Hydrogen (~15 wt. % H in polymer) 4

The 1 tonne of the product patties was charged into a hot heel of theelectric arc furnace. The effect of the addition of the charge of theproduct was monitored via cameras and standard data recording ofchemistry and method operating parameters.

The heat balance for the addition is set out below.

Product 1,000 kg = 680 kg FeO (510 kg Fe) + 240 kg LDPE + 70 kg CokeHeat In 240 kg LDPE × 12.9 kWhr/kg = 3,096 kWhr Heat Out Iron oxidereduction = 2 kWhr/kg* × 680 kg = 1,360 kWhr Iron melting = 510 kg ×0.44 kWhr/kg × 225 kWhr Balance 3,096 − (1,360 + 225) = +1,511 kWhr

It is noted that the above heat balance is based on theoretical datafrom standard reference materials and data obtained from an electric arcsteelmaking plant of the applicant in NSW, Australia.

Some key findings of the trial are as follows.

-   -   The product patties were a source of energy.    -   The product patties were magnetic—therefore, the patties could        be handled using a standard furnace scrap magnet crane—˜500        kg/load.    -   The product patties were tough—no breakage with regular blocks.    -   The product patties were waterproof—no noticeable weight        increase submerged in water for 1 week.    -   The product patties settled at the bath/slag interface and        started reacting within the furnace.    -   The product patties remained intact and reacted at a controlled        rate for extended period with some patties lasting >15 minutes.    -   The product patties produced strong heat generation.    -   There was very little fume generation compared to plastic and        rubber alternative products.    -   Charge reaction—no noticeable change adding 100 kg, 200 kg and        300 kg/heat in bottom bucket 1.

The results of the trial indicate significant business opportunitiesbased on the composite product of the present invention.

In particular, the applicant realised from the trial that a compositeproduct of the present invention that is based on a polymeric materialbinder that holds together carbon-bearing material could be asignificant source of energy that has wider applications than thesteelmaking industry, with these applications including as a replacementfor fossil fuels in power stations and kilns, such as cement makingkilns, and other applications that require heat to be generated byfossil or engineered fuels.

In addition, the applicant realised from the trial that a compositeproduct of the present invention makes it possible to introducedifferent ratios of steelmaking feed materials and sources of energy ina charge bucket to an electric arc furnace. Hence, depending on therequirements, there may be more or less of each of the iron-bearingmaterials and other steelmaking feed materials and the polymericmaterial (as a binder and a source of energy) in a charge bucket. Hence,the composite product of the present invention provides an opportunityfor flexibility in the supply of feed materials to a steelmaking processand, in particular, an opportunity to optimise energy utilisation.

Another key benefit of the sample product patties, which is a benefitthat should facilitate use of the composite product of the invention inelectric arc furnaces and other high temperature methods is that thereis a controlled and metered rate of reaction and heat generation becauseof the physical and chemical composition of the product patties. Thecontrolled rate of fuel release leads to complete combustion andutilisation of heat in a furnace rather than in the offgas system.Therefore, there is a lower risk of high gas duct temperatures and baghouse trips as well as unburnt fuel or fume in the off-gas duct leadingto explosions. In the 1 tonne trial it was observed that the sampleproduct patties (−3 kg each) took longer than 10 minutes to combust whenadded to the hot heel of the furnace. This was a key observation andsignificant benefit and should allow the sample product patties to beused like “burners” under scrap charge at a controlled rate duringmeltdown rather than reacting too fast immediately after charging andcausing fume and flame to exit the furnace. In comparison, when a smallamount of plastic film bound together or pieces of rubber tyre was addedto the furnace it reacted and was burnt within a few minutes. The sampleproduct patties were observed to ignite and sustain a strong flame for along period.

Based on the trial, the applicant believes that if the composite productpatties are located under the scrap in an electric arc furnace, theproduct patties will potentially provide preheating and reduce the poweron time and electrical energy consumption.

The slower rate of combustion of the product patties was controlled inthe trial due to the composite nature of the composite product. Thereaction of the polymer material binder or filler materials (mill scaleand coke fines) with oxygen was limited to the surface of the productpatties due to the low porosity caused by the binder. Therefore, therewas very little gas penetration into the product patties. The lowporosity limited the surface area for reaction and shielded thereactants within the product. There should be a large thermal gradientfrom the inside to the surface of the product with reaction taking placeon or near to the surface. There would also be some insulation effectfrom the gas/fume/flame layer formed by the fuming and ignition of thepolymer at relatively low temperature (250 to 400° C.) and reactionproducts leaving the surface of the briquette. For example, this shouldinsulate the product patties from the surrounding high temperature steeland slag (1500-1750° C.) and allow the product patties to last longer.

Fuel is released at a controlled rate as only that exposed at thesurface reacts.

The composite matrix structure of the product patties means that theiron oxide shields the polymer binder and controls the reaction rate. Ifthe filler material has low combustibility, then the rate of supply of a“fuel” to the surface where it can contact oxygen is lower. That is whythe iron oxide (mill scale) products would potentially last longer inliquid metal slag than briquettes that contain combustible filler likecoke or graphite. The same shielding effect could be achieved by usingother filler materials with low rate of combustion (lime, dolomite,baghouse dust, etc.).

The products also slow down the reaction compared to if the finematerials were added individually. For example, both mill scale and cokefines can react quickly or violently through a carbon oxygen reactionwhen introduced to a liquid steel bath due to the high surface area ofthese materials.

It follows from the above discussion that the rate of reaction could becontrolled by varying the composition of the product patties to increaseor decrease the filler and binder materials. This could be applied tomany pyrometallurgical applications or other high temperatureapplications. For example, the applications include mini-blast furnacesor alternate iron making processes or incineration processes or powergeneration processes.

In the context of the electric arc steelmaking industry, the trialindicated that the composite product of the present invention providesopportunities for scrap replacement, the use of waste products andby-products produced in steelmaking plants and in other industries, theuse of feed materials in the form of fines that otherwise would not besuitable for use in electric arc steelmaking furnaces, the use ofrecycled materials as the polymer material binder and as a source ofenergy, and the opportunity for selective layering of charges in anelectric arc furnace to optimise heat generation and other reactions.The opportunities translate into environmental and financial benefits.

The present invention has the following features and advantages, whichare described to a large extent in the context of the use of thecomposite product of the invention in a steelmaking application but alsoapply to other end-uses of the product:

-   -   The polymeric material binder produces a very tough and in many        instances a water-proof product, meaning less product breakdown        and longer shelf life in materials handling.    -   There are additional advantages when the product has a covering        of the polymeric material that encapsulates fines and larger        size particles in the product. Encapsulation of the fines and        larger size particles in the polymeric material may make it        possible to store the product outside without appreciable        moisture pick-up. Also, more generally, encapsulation provides        protection against moisture pick-up/hydration when the product        is exposed to atmosphere in any storage situation. In addition,        encapsulation of the fines and larger size particles in the        polymeric material may prevent or at least minimise leaching of        compounds from the product. For example, encapsulation of        electric arc furnace dust containing heavy metals in a composite        product of the invention to prevent leaching of heavy metals may        be an advantage in handling, storage and transportation of the        product.    -   The polymeric material acts as a “clean” binder to carry fines        into a high temperature method. The fines are consumed in the        furnace and the polymeric material binder exits system as a gas        (for example, low density polyethylene melts at 115° C. and        vaporises ˜350° C.).    -   The carbon and hydrogen components of the polymeric material        binder may assist in combustion/reduction based methods.    -   The use of the polymeric material acting as a binder could be        applied to any suitable high temperature method and not only        high temperature methods in metallurgical furnaces.    -   The hot extrusion process is suitable for large scale and        economically viable production of both product types, namely one        product type being based on metal-bearing material and the other        product type being based on a carbon-bearing material.    -   Size control for the polymeric material binder is potentially        less stringent due to melting during extrusion process.    -   The use of recycled polymeric materials as the binder may        attract environmental benefit as many polymeric materials would        be otherwise sent to landfill.    -   Hot extrusion technology is potentially applicable to any        industry requiring the recovery, transport and processing of        fines, including metal-bearing and carbon-bearing fines.    -   The product is magnetic when it contains iron-bearing units.    -   The use of the product in an electric arc steelmaking method was        energy positive in overall terms.    -   The use of the product under and within a scrap charge for an        electric arc steelmaking method facilitates close contact        heating of the scrap charge and potentially improved heat        transfer and efficient use of energy.    -   The use of a hot extruder makes it possible to use feed        materials with higher moisture contents due to heating in the        extruder.    -   The invention makes it possible to use feed materials in the        form of fines.

Many modifications may be made to the present invention described abovewithout departing from the spirit and scope of the invention.

1. A method of manufacturing a composite product in the form of (a) apolymeric material binder and a metal-bearing material or (b) thepolymeric material binder and a carbon-bearing material that comprisesheating and mixing the components of the composite product andthereafter forming the heated mixture into a final product shape, withthe heating step being sufficient to melt at least a part of thepolymeric material binder to facilitate forming the product.
 2. Themethod of manufacturing the composite product that comprises thepolymeric material binder and the metal-containing material defined inclaim 1 includes mixing sources of carbon other than the polymericmaterial binder, with the metal-bearing material and the polymericmaterial. 3-5. (canceled)
 6. The method defined in claim 1 comprisesmixing the metal-bearing material and the polymeric material binder sothat there is a uniform dispersion of the metal-bearing material throughthe product.
 7. The method defined in claim 1 comprises mixing thecarbon-bearing material and the polymeric material binder so that thereis a uniform dispersion of the carbon-bearing material through theproduct.
 8. The method defined in claim 1 comprises heating the mixtureof the components of the product at a temperature that is sufficientlyhigh to completely melt the polymeric material binder. 9-12. (canceled)13. The method defined in claim 1 includes forming the heated mixtureinto the composite product by extruding the heated mixture.
 14. Acomposite product comprises a metal-bearing material and a polymericmaterial that acts as a binder for the metal-bearing material.
 15. Theproduct defined in claim 14 comprises other materials, such as materialsthat are sources of carbon other than the polymeric material binder. 16.A composite product comprises a carbon-bearing material and a polymericmaterial that acts as a binder for the carbon-bearing material.
 17. Theproduct defined in claim 16 comprises a metal-bearing material.
 18. Theproduct defined in claim 14 comprises a continuous network of thepolymeric material and a uniform dispersion of the metal-bearingmaterial.
 19. (canceled)
 20. The product defined in claim 14 comprisesan outer covering of the polymeric material 21-22. (canceled)
 23. Theproduct defined in claim 14 wherein the polymeric material is a recycledpolyethylene such as a low density polyethylene or a high densitypolyethylene or a recycled polypropylene. 24-25. (canceled)
 26. Theproduct defined in claim 14 being made completely from recycledmaterials, with each of the polymeric binder material and themetal-bearing material being recycled materials. 27-29. (canceled)
 30. Amethod for producing a molten metal that comprises supplying thecomposite product defined in claim 14 as a feed material for the method,with the composite product being formed by the method defined in claim 1with sufficient strength and toughness to be able to be handled within ahigh temperature processing plant for carrying out the method ofproducing the molten metal and to be charged into a high temperaturefurnace in the plant without significant breakdown of the product intosmaller sized products, with generation of fines outside and/or insidethe furnace.
 31. A method for producing a molten metal that comprisessupplying the composite product defined in claim 14 as a feed materialfor the method, with the composite product being formed by the methoddefined in claim 1 to be sufficiently large and have required mechanicalproperties such as strength to withstand high temperature and reactiveconditions in a high temperature furnace in a high temperatureprocessing plant for carrying out the method to facilitate controlleddissolution of the product in the furnace over a required time period.32. The product defined in claim 16 comprises a continuous network ofthe polymeric material and a uniform dispersion of the carbon-bearingmaterial.
 33. The product defined in claim 16 comprises an outercovering of the polymeric material.
 34. The product defined in claim 16wherein the polymeric material is a recycled polyethylene such as a lowdensity polyethylene or a high density polyethylene or a recycledpolypropylene.
 35. The product defined in claim 16 being made completelyfrom recycled materials, with each of the polymeric binder material andthe carbon-bearing material being recycled materials.
 36. A method forproducing a molten metal that comprises supplying the composite productdefined in claim 16 as a feed material for the method, with thecomposite product being formed by the method defined in claim 1 withsufficient strength and toughness to be able to be handled within a hightemperature processing plant for carrying out the method of producingthe molten metal and to be charged into a high temperature furnace inthe plant without significant breakdown of the product into smallersized products, with generation of fines outside and/or inside thefurnace.
 37. A method for producing a molten metal that comprisessupplying the composite product defined in claim 16 as a feed materialfor the method, with the composite product being formed by the methoddefined in claim 1 to be sufficiently large and have required mechanicalproperties such as strength to withstand high temperature and reactiveconditions in a high temperature furnace in a high temperatureprocessing plant for carrying out the method to facilitate controlleddissolution of the product in the furnace over a required time period.